The engine of a Standard
2400 D Aspirated engine of a 1991 VW T4 Transporter without turbo (as it was
before…)

The old 1991 Volkswagen Transporter 2400
Diesels has a really reliable engine; alas it has the standard limits of all the
old mechanically aspirated engines: the highway maximum speed is approximately
120 km/h (78 M/h), moreover, in mountains where the roads are normally steep, it
can force the driver to drive too often just in second gear. In general this old
engines have a limited pick-up, especially on uphill roads and off road.

To limit these problems on my VW
aspirated Transporter 2400 AAB engine I installed a turbocharger.

OEM reference number of
the turbocharger of a VW Transporter TDI 2500 of 1996

The best and economical option to do
this tuning is to install the manifold intake, the exhaust manifold and the
turbocharger of a VW Transporter TDI 2500, ACV engine, 5 cylinders, year 1996.
The 1996 T4 Tdi has a similar engine block. The Tdi spares can be found second
hand or rotation at a reasonable price. Rotation or new Tdi spares can be found
searching in ebay, the keywords are: (T4 Tdi) "krümmer" (collector);
"turbolader" (turbo); "Abgaskrümmer" (exhaust manifold);
"Dichtungen" (gaskets); "Ansaugkrümmer" (manifold intake)
all for the VW T4 TDI 1996.

Please remember that the 2400 Aspired are
old engines and therefore you does not have to "pump it" too much
exaggerating with the pressure
of the turbo!: 0.45 bar is ok.

The pressure of a turbo can be expressed
in Bar or PSI (Pounds For Square Inch): 1 Bar is equivalent to 14.7 PSI
therefore 0,45 Bar is 6,5 PSI (or 0,4 Atm). A standard big turbocharger on a new
engine can work with a pressure of 1,2 Bars but such high values of pressure are
not safe with our old engines ! The important is to install the turbocharger
reducing the pressure (we regulated it to approximately 0.45 bar) and to leave
the diesel pump, EGR and injectors, as they already are, installing merely the
manifold & turbo parts of a TDI. Just give some more diesel to the
injectors, that is all.

The final result: Turbo
& manifolds of a 2500 TDI install on the engine of my 2400 D

Is good to know that the head engine
gasket of the Aspirated T4 2400 D was already a "turbo-type" gasket.
Moreover the T4 2400 D the oil filter had already the nozzle for the oil of the
turbo.

On my T4 California 2500 D Aspirated we
have installed the turbo with a pressure of just 0.45 Bar.

The result has been quite good. Clearly I
did not get a considerable increase of speed, mainly because we left the turbo
pressure low and we did not change any diesel pump settings ecc. Besides the
pick-up is now good! The T4 is a reasonably better in overtaking other vehicles,
even in uphill roads, the acceleration time is shorter and in steep slopes I do
not have to reduce gear too often like I usually did before.

Remember that the installation is on
your own risk. I do not take responsibilities of any kind: tuning up an old
engine is fun, but always uncertain.